Process of making polyacrylonitrile fibers

ABSTRACT

A process for preparing a PANOX fiber comprising: obtaining an acrylonitrile copolymer, wherein the copolymer contains at least about 2% by weight itaconic acid comonomer; forming a spin dope from the copolymer; wet spinning the spin dope to obtain gelled filaments; contacting the gelled filaments with ammonia activator in an aqueous imbibation bath; bundling the gelled filaments to obtain a fiber; removing solvent from the fiber; drawing the fiber; densifying the fiber by heating the fiber up to about 400 degrees C. for a time of about 15 minutes in a rapid densification zone; and withdrawing a PANOX fiber from the densification zone.

This is a divisional of U.S. application Ser. No. 13/761,565, which wasfiled on Feb. 7, 2013, which is a divisional of U.S. application Ser.No. 12/585,304, which was filed on Sep. 10, 2009, which is now U.S. Pat.No. 8,372,323, with grant date of Feb. 12, 2013; and is based on U.S.patent application Ser. No. 12/073,376 which was filed on Mar. 5, 2008and is now U.S. Pat. No. 7,964,134; and is based on U.S. patentapplication Ser. No. 11/311,246 which was filed on Dec. 20, 2005 and isbased on U.S. provisional application 60/636,887 filed on Dec. 20, 2004.

BACKGROUND OF THE INVENTION

The prior art processes for the preparation of either PANOX (oxidizedpolyacrylonitrile) fibers or carbon fibers employs high heat andextended periods of time to obtain the final product. The final PANOXfiber or carbon fiber product in the prior art is often a flawed productthat contains weak spots and micro-bubbles. This is because presentprocesses do not control the rapid increase in heat when the fiber isheated above its fusion point. The prior art strategy increases thetemperature of a PAN (polyacrylonitrile) fiber to just below its fusionpoint. Then the PAN fiber is SLOWLY heated for an extended period oftime (approximately 3-4 hours). “Burn out” of the fiber is thus avoided.“Burn out” of the fiber occurs when the temperature of the fiber reachesthe fusion point of the fiber. The internal temperature of the fiberthen rapidly shoots up to 400 degrees C. and above. The result is thatthe fiber is destroyed. The fiber employed in prior art processes doesnot begin to cross-link until late in the heating cycle (near the fusionpoint of the fiber). Thus, the prior art methods depend on slowing downthe heating process, and then slowly raising the temperature over thenext couple of hours.

Prior art processes for preparing either PANOX fiber or carbon fiberinclude the use of about three or four monomers for preparing apolyacrylonitrile copolymer. The monomers can be: acrylonitrile (90-98%by wt.), itaconic acid (2-10% by weight), ethyl acrylate (2-5% by wt.),and vinyl sulfonic acid (1-3% by weight). In a first step, the fourmonomers are polymerized as by a precipitation polymerization process inthe presence of a Redox catalyst. The resultant polyacrylonitrilecopolymer is then wet spun into fibers. The fibers have a density ofabout 1.2 grams/cc. The PAN (polyacrylonitrile) fibers are then removedto a first oxidation zone. The fibers are SLOWLY heated in an energyintensive process for a time of about 3-4 hours. The process iscarefully monitored to prevent runaway heating from the interior of thefibers. This process is not cost effective because of the extendedheating cycle.

PANOX (oxidized polyacrylonitrile) fibers are withdrawn from the firstoxidation zone. The density of the PANOX fibers is about 1.4 grams/cc.The PANOX fibers can be used in areas of technology such as sportingequipment and the like. If pristine carbon fibers are desired, the PANOXfibers are removed to a second oxidation zone which is a hightemperature carbonization unit. Temperatures in the carbonization unitare from 1000-2000 degrees C., or even higher. All atoms other than thecarbon atoms are vaporized away from the fibers to obtain a pristinecarbon fiber.

U.S. Pat. No. 5,462,799 discloses the preparation of a carbon fiberwherein a precursor PAN-fiber is oxidized, carbonized and if necessarygraphitized to make the carbon fiber.

U.S. Pat. No. 5,281,477 discloses the preparation of a carbon fiberhaving high tenacity and high modulus of elasticity. Pretreated fibersare passed through a series of three carbonization zones.

The problems of the current methodology for preparation of carbon fiberare as follows: (1) failure to recognize the fact that amidines are thetrue initiators in the preparation of carbon fiber; (2) failure torecognize that metal ions “poison” the fiber at every step of theprocess; and (3) failure to recognize that the first oxidation step canbe performed in a substantially reduced time frame.

Therefore there is a need for a process of preparing superior PANOXfiber or carbon fiber that overcomes the drawbacks of the prior art.

SUMMARY OF THE INVENTION

The present invention relates to an improvement in the process forpreparing PANOX fiber or carbon fiber in accordance with the disclosuresfound in U.S. Pat. No. 5,804,108; issued to Wilkinson; U.S. Pat. No.6,054,214, issued to Wilkinson, and US PGPUB 2006/0134413, submitted byWilkinson, incorporated in their entirety herein by reference. Thedisclosures of the '108, '214 patents and the '413 publishedapplication, rely on the preparation of a uniquely balanced polymericprecursor in order to achieve a carbon fiber precursor (a PANOX fiber)that has superior modulus when compared with prior art PANOX fiber. Themodulus of the fiber is improved by at least 2 and ½ times when comparedwith prior art PANOX fibers.

The present invention relates to a process for preparing a PANOX fibercomprising: obtaining an acrylonitrile copolymer and forming a “spindope”. The “spin dope” is added to a wet spinning zone, wherein the wetspinning zone comprises a die plate. In a preferred embodiment, the dieplate contains 2100 holes. Thus 2100 filaments can be obtained from asingle die plate. The “spin dope” is passed through the die plate toobtain gelled filaments. The gelled filaments have a substantiallycircular cross-section. Without removing solvent from the filaments, thegelled filaments are added to an aqueous imbibation bath containing anactivator such as ammonia. The gelled filaments are under minimumtension. Minimum tension refers to a pull on the filaments that is ofstrength substantially sufficient to move the filaments from the dieplate to the aqueous imbibation bath, but without drawing the filaments.Preferably, the tension on the filaments is substantially zero. In anembodiment of the present invention, the gelled filaments are pulled bygravity into the imbibation bath without tension placed on thefilaments. It is critical to the process of the present invention thatthe filaments enter the aqueous imbibation bath in a gelled state. Thusthe filaments cannot be drawn or washed, since drawing causes thefilaments to solidify and form an outer skin; and washing of thefilaments removes the solvent inherent in the filaments, causing thefilaments to be in a non-gel state.

The aqueous imbibation bath comprises water and an activator.Preferably, the activator is a member selected from the group consistingof low molecular weight primary amine, low molecular weight secondaryamine and ammonia. By “low molecular weight amine” is meant an organicamine compound containing one to six carbon atoms. The gelled filamentsare imbibed with the activator to obtain activator-loaded gelledfilaments. The activator-loaded gelled filaments are removed from theaqueous imbibation bath. They are then bundled or combined on an uptakereel or the like to obtain an activator-loaded fiber. The fiber is thenadded to a solvent extraction zone which comprises an aqueous draw bath.Solvent is removed from the activator-loaded fiber. Also, the fiber isdrawn about 7× to about 9× while in the bath to obtain a drawn fiber.The drawn fiber has a density of about 1.18 grams per cubic centimeter.The drawn fiber is optionally passed over a series of heated rolls toobtain a relaxed fiber. In a preferred embodiment, the fiber is relaxedabout 8% to about 12%. The fiber is then added to a rapid densificationunit. In a preferred embodiment, the rapid densification unit comprisesa set of three heating rolls. The fiber is heated for about 8 minutes toabout 15 minutes in the rapid densification unit. The heating step isconducted sequentially, by employing a heating cycle beginning at about190 degrees C. and ending at about 400 degrees C., to obtain the PANOXfiber. The density of the heated fiber is about 1.40 grams per cubiccentimeter to about 1.5 grams per cubic centimeter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow diagram of a process for preparing PANOX fiberaccording to the present invention.

FIG. 2 is a representation of an aqueous imbibation bath of the presentinvention.

FIG. 3 is a representation of a rapid densification unit of the presentinvention.

FIG. 4 is a representation of an alternative embodiment of the rapiddensification unit of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present process overcomes the failures of the prior art processes aspracticed today. In a preferred embodiment, two monomers comprisingacrylonitrile (95% by wt.) and itaconic acid (5% by wt.) are added to aprecipitation polymerization reactor along with a redox catalyst. Thecatalyst is preferably a bisulfite catalyst. No metal-containing ormetal ion-containing solvents are employed. No vinyl sulfonic acidmonomers are employed. An acrylonitrile copolymer is removed from thepolymerization reactor, purified, dried and then emulsified with asolvent such as DMF to form a “spin dope”. The “spin dope” is then addedto a wet spinning zone for spinning into PAN (polyacrylonitrile)filaments. The PAN filaments have a density of about 1.18 grams/cc. Thewet spun PAN filaments, while still in the gel state, are then added toan aqueous imbibation bath. The wet spun PAN filaments contain asubstantial amount of solvent. The aqueous imbibation bath containswater and ammonia. The ammonia is present in the bath in an amount ofabout 5% by volume to about 10% by volume. The temperature of the bathis maintained at about 40 degrees C. to about 80 degrees C. Preferably,the temperature of the aqueous imbibation bath is about 60 degrees C.The filaments are in a gel state. Ammonia activator penetrates into thegelled filaments in a substantially uniform fashion in a time of about 5milliseconds. Activator-loaded gelled filaments are then withdrawn fromthe aqueous imbibation bath. They are then bundled or combined into anactivator-loaded fiber.

The fiber is added to a solvent extraction unit. The solvent extractionunit comprises an aqueous draw bath comprising water. The temperature ofthe aqueous draw bath is maintained at a temperature of about 100degrees C. Solvent is removed from the fiber. Also, the fiber isstretched about 7×. The drawing of the fiber in the aqueous draw bathallows for development of superior physical properties in the PAN fiber.In an alternative embodiment, the activator-loaded fiber is not added toa solvent extraction unit, but rather added to a set of heated rolls forstretching. The rolls are maintained at a temperature of about 160degrees C. Solvent is removed and captured as the fiber passes over therolls.

The PAN fiber is then removed to a rapid densification unit. Oxygen isnot needed for the rapid densification step, but it does not need to beexcluded. Preferably, the fiber is heated for a time of about 12minutes. The heating of the fiber is always below its fusion point.Heating begins at about 190-200 degrees C. and ends at about 400 degreesC. The preferred heating cycle is to heat the fiber at 240 degrees C.for four minutes, then to heat the fiber at 250 degrees C. for fourminutes, and finally to heat the fiber at 260 degrees C. for anotherfour minutes. A densified fiber (PANOX fiber), is then removed from therapid densification unit. This densified fiber is called a PANOX fiberin the present description, even if the fiber is densified in anenvironment that excludes oxygen. The fiber has a density of about 1.4grams/cc to about 1.6 grams/cc.

The acrylonitrile (PAN) copolymer is prepared from a mixture ofcomonomers, the mixture containing acrylonitrile monomer in an amount ofabout 95% by weight, and itaconic acid in an amount of about 5% byweight. The wet-spun PAN copolymer gelled filaments are immersed in anaqueous imbibation bath containing an excess of ammonia. By “excess ofammonia” is meant that there is more than enough ammonia present in theaqueous bath to react with all of the pendant carboxylic acid groupspresent in the PAN copolymer. While immersed in the aqueous imbibationbath, the filaments are imbibed with ammonia, as ammonia activatorpenetrates into the central regions of the filaments. The filaments areimbibed with activator in a time of about five milliseconds. Theactivator is homogeneously dispersed throughout the fiber. In prior artmethods, activator remains on or near the surface of the fiber, withpossibly a minor amount of activator penetrating to the core of thefiber.

Referring to FIG. 1, a flow diagram of a process for preparing PANOXfiber according to the present invention is presented. An acrylonitrile(PAN) copolymer 1 is added to a solvent 2 such as DMF to prepare a “spindope”. The “spin dope” is then transferred to a spinning unit 5 as byfirst transfer means 4. In a preferred embodiment, the spinning unit 5is a wet spinning unit. Wet spinning allows formation of filamentshaving substantially circular cross-sections. Dry spinning causes thefilaments to have dog-bone shaped cross-sections, which shape is notdesirable for preparing PANOX fiber.

Wet spun filaments are removed from the spinning unit 5, and enter theaqueous inbibation bath 8. Second transfer means 7 removes the wet spunPAN filaments, which have a density of about 1.18 g/cc., from thespinning unit 5. The filaments are transferred to the aqueous inbibationbath 8. The aqueous imbibation bath 8 comprises water and ammonia. Theammonia activator is present in the bath in an amount sufficient toreact with all of the carboxylic acid groups in the wet spun PANfilaments. The carboxylic acid groups pendant from the PAN copolymerbackbone are a result of the itaconic acid monomer used in apolymerization reaction for preparing the PAN copolymer. Ammoniamolecules are grabbed by the pendant carboxylic acid groups to form anorganic salt complex. This formation of salt complexes is complete inabout 5 milliseconds.

Activated PAN filaments (filaments that have salt complexes pendant fromtheir polymeric backbone) are then removed from the aqueous imbibationbath 8 as by a third transfer means 9. The activated PAN filaments arethen bundled or combined into a PAN fiber in a collection unit 15. Afourth transfer means 11 receives the activated PAN fiber and removes itto a solvent extraction zone 12 which comprises an aqueous draw bath anda device for drawing the fiber. While immersed in the aqueous draw bath,the activated PAN fiber is drawn at least about 7× to set the physicalproperties of the fiber. Also, solvent is removed from the fiber. Thedrawn PAN fiber can then optionally be added to a relaxation zone 10,which can comprise a set of steamed rollers, in order to relax the drawnPAN fiber. Drawn PAN fiber is relaxed at least about 8% to about 12%.Preferably, the PAN fiber is relaxed about 10% in the relaxation zone10.

The drawn PAN fiber, imbibed with activator, is removed as by sixthtransfer means 13 to a rapid densification unit 14. In a preferredembodiment, the rapid densification unit 14 comprises a set of threeheating rolls (not shown). A first heating roll is maintained at atemperature of about 240 degrees C. The drawn PAN fiber remains on thefirst heating roll for a time of about 4 minutes. It is then removed toa second heating roll that is maintained at a temperature of about 250degrees C. The drawn PAN fiber remains on the second heating roll for atime of about four minutes. It is then removed to a third heating rollthat is maintained at a temperature of about 260 degrees C. The drawnPAN fiber remains on the third heating roll for a time of about fourminutes. Thus, the total amount of time that the PAN fiber remains inthe rapid densification unit 14 is about twelve minutes. A densified PANfiber (PANOX fiber) is removed from the rapid densification unit 14.This PANOX fiber, although not the same as pristine carbon fiber, can beemployed in many areas of technology.

If pristine carbon fiber is desired, PANOX fiber is removed as by aseventh transfer means 19 to a carbonization unit 20 which contains aninert atmosphere such as nitrogen gas or the like. The conversiontemperature in the carbonization unit 20 is in the range of about 1000degrees C. to about 2000 degrees C. or higher. The PANOX fiber isconverted into pristine carbon fiber. The pristine carbon fiber containsonly carbon atoms in its molecular structure.

Referring to FIG. 2, an aqueous imbibation bath 8 is represented. Theaqueous imbibation bath 8 contains an amount of water solution 50sufficient to immerse gelled filaments 52, wherein the filaments areexiting from a die plate in a wet spinning unit (not shown). A watersolution 50 in the aqueous imbibation bath 8 contains an amount ofammonia or some other activator (a low molecular weight primary orsecondary amine). The ammonia (or other activator) is present in anamount sufficient to neutralize all of the pendant organic carboxylicacid groups on an acrylonitrile copolymer that was employed in preparinggelled filaments 52. In an embodiment of the present invention, theaqueous imbibation bath 8 is maintained at a temperature of about 60degrees C. Gelled filaments 52 are passed over a feed roll 53 and enterthe ammoniacal water solution 50. Ammonia activator is imbibed by thefilaments 52. Filaments 52 are withdrawn from ammoniacal water solution50 by uptake roll 55.

Referring to FIG. 3, a rapid densification unit 25 of the presentinvention is represented. The rapid densification unit 25 comprises asealed chamber 30. The sealed chamber 30 can be an elongated cylindricalheating tube with an opening at both ends. Each end of the tube can thenbe sealed with an airtight covering 31 once the fiber is placed in thetube. In an embodiment, the sealed chamber 30 can contain an inertatmosphere. The inert atmosphere can be nitrogen gas, argon gas or thelike. However, it is not necessary to exclude oxygen, and air can bepresent in the sealed chamber 30. Inside the sealed chamber 30 areadjustable heating coils 32. The heating coils 32 are programmed toincrease the temperature in a predefined heating cycle. Preferably, thepredefined heating cycle begins at about 190 degrees C. and ends atabout 400 degrees C.

Referring to FIG. 4, a continuous process and apparatus for the rapiddensification of an activator-loaded PAN fiber is represented. A rapiddensification unit 40 comprises a set of three heating rolls (41, 42 and43) maintained at sequentially higher temperatures. In an embodiment,the first heating roll 41 is maintained at a temperature of about 235degrees C. to about 245 degrees C. The second heating roll 42 ismaintained at a temperature of about 245 degrees C. to about 255 degreesC. The third heating roll 43 is maintained at a temperature of about 255degrees C. to about 265 degrees C. It is within the scope of the presentinvention to employ other heating cycles, wherein the cycles are withinthe range of about 190 degrees C. to about 400 degrees C.Activator-loaded PAN fiber 44 passes over feed roll 45 and is taken upby first heating roll 41. The process of densification of the fiber 44begins on the first heating roll 41. The fiber 44 is then moved to thesecond heating roll 42 for further densification. Finally, the fiber 44is moved to the third heating roll 43 to complete the densification ofthe fiber. When the fiber 44 is removed from the third heating roll 43,it is advanced by uptake roll 46. The fiber density has increased fromabout 1.18 grams/cc to about 1.4 grams/cc. In an alternative embodiment,the set of three heating rolls (41, 42 and 43) can be located in asealed container 48 in the absence of air. The sealed container isprovided with an inert atmosphere such as nitrogen gas or argon gas.

PANOX fibers that have a density of less than about 1.4 g/cc. cannot becarbonized to obtain pristine carbon fiber because they will undergo a“flame-out” at carbonizing temperatures, such as 1000 degrees C. This isdue to the volatiles that remain in the fiber.

The present invention relates to a process for preparing a PANOX fiberthat does not undergo “flame-out” at carbonizing temperatures. PANOXfiber of the present invention also has an improved modulus, the modulusbeing up to 2 and ½ times higher than the modulus of prior art PANOXfibers. This increase in modulus is a result of less oxidativedegradation of the fiber during the heating cycle in the densificationunit. Heat release begins at a much lower temperature than in the priorart. The internal heat of the PANOX fiber is released over a wide range(about 100 degrees) of heating. The heat release is also conducted overa substantially longer time interval, rather than a sharp spike. Theinternal heat of the fiber, generated because of chemical cross-linkingreactions, is removed in about 15 minutes rather than a spike of 3seconds. The entire densification step is therefore conducted aboutthree to five times faster than in prior art methods of oxidativelypreparing PANOX fibers.

In the present invention, improvement begins with the first step of thecarbon fiber process, the first step being the polymerization ofmonomers. In a preferred embodiment, monomers chosen for polymerizationare acrylonitrile and itaconic acid. The itaconic acid is present in anamount of about 2% by weight to about 8% by weight. Preferably, theamount of itaconic acid is about 5% by weight. Itaconic acid is adicarboxylic acid, and therefore supplies twice as many anchors forretaining amine (or ammonia) catalyst as does (meth)acrylic acid or thelike. Most preferably, monomers are present in the following amounts:95% by weight acrylonitrile and 5% by weight itaconic acid. The monomersare polymerized by a reaction such as a precipitation polymerizationreaction or a solution polymerization reaction. Most preferably, aprecipitation polymerization reaction in aqueous phase is employed. Theprecipitation polymerization is conducted in the presence of a catalystregime comprising ammonium persulfate, potassium bisulfite and about 10ppm iron. The amount of iron catalyst is kept at a minimum to avoidpolymer degradation. An azo initiator can also be employed. The reactionis conducted at a temperature of about 60 degrees C. to about 80 degreesC. An aluminum shell reactor containing a water jacket shell can beemployed.

A solution polymerization reaction can be employed. The catalysts forthe reaction are preferably an azo initiator and ferrous ammoniumsulfate. The reaction is conducted at a temperature of about 60 degreesC. to about 80 degrees C. The reaction is conducted for a time of about20 minutes to about 90 minutes. Preferably, the reaction is conductedfor a time of about 60 minutes.

When the polymerization reaction is complete, the reaction mixture isfiltered to remove water. A polyacrylonitrile (PAN) copolymer isrecovered from the filtration process. A filter cake is formed. Thefilter cake is re-slurried in water. Water is removed by decantation orthe like. The copolymer is dried to a powder in a drying unit.Preferably, the dry powder is obtained by dropping copolymer noodlesonto a porous moving belt. Hot air passing through the belt dries thenoodles of copolymer. Noodles are then pulverized to obtain the drypowder.

A mixer can be employed to form a spin dope. Preferably, the spin dopeformation unit is a MARCO MIXER. The acrylonitrile dry powder is addedto the MARCO MIXER, along with dimethylformamide (DMF), which is sprayedinto the mixer. The mixer is heated to a temperature of about 60 degreesC. to about 100 degrees C. A mixture of acrylonitrile copolymer and DMFis formed, the mixture having the consistency of honey. In analternative embodiment, DMF can be replaced with DMAC(dimethylacetamide).

The mixture of acrylonitrile copolymer and DMAC (dimethylacetamide) isthen removed to an extrusion unit. An aqueous bath of DMAC (or DMF) andcopolymer is then formed. The aqueous bath, called a coagulation bath,is maintained at a temperature of about 25 degrees C. to about 50degrees C. Fine filaments of copolymer are extruded through a die platefrom the coagulation bath. The filaments have a dernier of about 1 toabout 8. The extrusion unit can be a dry spinning operation or a wetspinning operation. Preferably, a conventional wet spinning apparatus isemployed. Any metal-containing, or metal ion-containing, solvents areavoided. Wet spinning of the spin dope allows formation of gel filamentsthat have a substantially circular cross-section.

The filaments are transferred to an aqueous imbibation bath withoutremoval of solvent. Filaments are in the gel state, and have anamorphous character. The imbibation bath contains an activator which isa member selected from the group consisting of a low molecular weightprimary amine, a low molecular weight secondary amine and ammonia. By“low molecular weight” is meant an amine that contains a C1 to C6aliphatic group. Preferably, ammonia is the activator. The ammonia ispresent in the imbibation bath in an amount of about 1% by volume toabout 5% by volume. Ammonia activator must be present in the imbibationbath in an amount sufficient to neutralize all of the carboxylic acidgroups present in the acrylonitrile copolymer. The carboxylic acidgroups are due to the presence of the itaconic acid monomer in thecopolymer. The imbibation bath, an aqueous bath that contains activator,is maintained at a temperature of about 50 degrees C. to about 70degrees C. Preferably, the temperature of the imbibation bath is about60 degrees C. The speed of the filaments traveling through theimbibation bath is in the range of about five yards per minute to abouttwo hundred yards per minute. Speeds are adjusted to obtain optimumresults. The imbibation bath is similar to the dye bath apparatusdisclosed and claimed in U.S. Pat. No. 3,944,386, issued to Wilkinson.

Ammonia activator uniformly penetrates the gelled filaments. The ammoniaactivator forms a salt with the carboxylic acid groups of the itaconicacid present in the PAN copolymer. The amount of itaconic acid (or thelike) in the copolymer determines the amount of activator (ammonia)“imbibed” into the filaments. The activator is homogeneously dispersedin each filament. Ammonium (or amine) salt remains unreacted anduniformly dispersed on a molecular basis until the copolymer is heatedto a temperature of about 160 degrees.

Filaments removed from the imbibation bath are preferably passed into afilament collection unit which gathers the filaments into a fiber.Larger tows can also be formed. The thus formed fiber or tow is passedinto a solvent extraction zone which comprises an aqueous bath. Withinthe aqueous bath is a device for drawing the fiber. This device can be aset of tensioning rollers. As the fiber enters the solvent extractionzone, solvent is washed from the fiber. The fiber is also drawn in arange of about 7× to about 9× to obtain a drawn fiber.

In an optional step, the drawn fiber is passed to a relaxation zonewhere the fiber is relaxed at least about 8%. The relaxation zonepreferably contains a set of steamed rollers. Water passes through therollers that are heated to a temperature of about 100 degrees C. Therollers have multiple outlets for steam. Steam contacts the drawn fiberas it passes over the set of steamed rollers. As a result of thecontact, the fiber is relaxed.

Fiber is then passed into a rapid densification zone. Densification ofthe fiber in the rapid densification zone can be performed in theabsence of air or oxygen. The theory is that oxygen does not cause thecrosslinking, but rather that the ammonia activator, upon gentleheating, forms amidine moieties within the polyacrylonitrile copolymer.The amidine moieties are the true initiators that cause densification ofthe fiber.

Because the amine activator (preferably ammonia) is homogeneouslydispersed throughout the PAN fiber, it is easy for the fiber to beheated in a short heating cycle, all the while keeping the temperaturebelow the fusion point of the acrylonitrile copolymer.

In an embodiment of the present invention, the rapid densification unitcan be a standard oven, such as a cylindrical heating tube, that canprovide heat for a time of about 8 minutes to about 15 minutes. Thetemperature at the start of the densification process is about 190-200degrees C. The final temperature at the end of the short heating cycleis about 400 degrees C. A densified PAN fiber (a PANOX fiber) is removedfrom the rapid densification zone. The density of the PANOX fiber isabout 1.4 grams/cc.

In an embodiment of the present invention, the densified fiber (PANOXfiber) is removed to a carbonization unit. The PANOX fiber is carbonizedin an inert atmosphere (eg., nitrogen gas) to obtain superior carbonfiber. The temperature of the carbonization unit is maintained at about1800 degrees C. to about 4000 degrees C. Preferably, the temperature isabout 2000 degrees C. Density of the carbon fiber is about 1.78 gramsper cc. to about 1.8 grams per cc. Carbonization is completed in abouttwo minutes. The carbonization operation can be compared to anincandescent light bulb, where a filament is stretched between twoelectrodes.

In the past, the densification step has been conducted for a time ofabout 1 to about 5 hours. The step is slow and adds significant expenseto the overall process. Process temperatures must be maintained belowthe fusion point of the fibers to prevent instantaneous temperaturesurges within the fiber. Temperature surges produce bubbles of gaseousproducts which ruin the physical properties of the carbon fiber. Theprior art densification step is conducted in an oxidizing atmosphere,usually in air, at a temperature of about 190 degrees C. to about 280degrees C. The reaction is an exothermic one, and a runaway reaction isalways possible.

It is another object of the present invention to provide a productcomprising an acrylonitrile copolymer which is substantially free ofmetal ions and sulfonic acid groups. The product is furthercharacterized by being prepared from acrylonitrile in an amount of about95% to about 98% based on weight; and vinyl carboxylic acid monomer inan amount sufficient to retain in the copolymer ammonium ion or aminecatalyst in amounts of about 1% to about 4% based on molar ratio, and,optionally, a vinyl carboxylic acid ester monomer in an amount up toabout 2% based on weight.

Once the acrylonitrile copolymer product is obtained, it can be sold asa precursor powder for preparation of a PANOX fiber in a rapiddensification stage. In an alternative embodiment, the copolymer productcan be wet spun, treated in an activator-containing aqueous imbibationbath and then drawn to obtain an activator-loaded PAN fiber. Such afiber can then be sold as a PANOX precursor fiber. The fiber can undergoa rapid crosslinking at both the intramolecular and intermolecularlevel. Rapid crosslink allows for swift increase in temperature withoutdetrimental side effects that would damage the fiber.

PANOX fiber prepared from activator-loaded PAN fiber by a rapiddensification process has superior physical properties. The PANOX fiberis useful as reinforcement material in automobile, aerospace,recreational and various other industries. An increasing demand forstrong lightweight materials insures an expanded use of carbon fiber inthe future. A fine quality acrylonitrile copolymer, such as describedabove, has no defects. A common defect is formation of voids in a fiberwhen gases are expelled during fiber preparation.

Carbon fibers, which have heretofore been used as reinforcing materialfor plastic composite compositions, are characterized by high tensilestrength, high rigidity and a homogeneous fibrous structure. Thesecharacteristics can be adversely affected by certain properties found inthe acrylonitrile copolymer feedstocks. If these undesirable propertiescan be identified and removed, then the final carbon fiber product isgreatly enhanced in desirable characteristics

Prior art processes employ a minor amount of itaconic acid (less than 2%by weight) when preparing the PAN copolymer. Itaconic acid is employedalong with a neutral monomer, eg., methyl methacrylate, to improveplastic flow and limit formation of internal bubbles in the fiber. Thepresent invention differs from the prior art in that it employs anamount of itaconic acid that is at least about 2% by weight. Theitaconic acid of the present process is employed to control spacing ofthe activator along the backbone of the PAN copolymer.

Neutral monomers slow down the densification reaction, and shouldtherefore be avoided. Examples of neutral monomers are methyl and ethylcarboxylates. The polyacrylonitrile copolymer is substantially free ofmetal ions and of groups which retain metal ions, other than thenecessary carboxylic acid groups. An example of a group which retainsmetal ions is the sulfonic acid group. Thus, vinyl sulfonic acid shouldnot be employed as a comonomer when the polyacrylonitrile copolymer isprepared.

In a preferred embodiment, a precipitation polymerization is employed toproduce the PAN copolymer. Such a process is disclosed in U.S. Pat. No.5,364,581, incorporated herein by reference.

The vinyl carboxylic acid comonomer which is employed in preparing thePAN copolymer is a member selected from the group consisting of itaconicacid, acrylic acid and methacrylic acid. Preferably, itaconic acid isthe comonomer. It is within the scope of the present process to use morethan one comonomer. The only restriction imposed on the present processis that a vinyl sulfonic acid comonomer, allyl sulfonic acid monomer,salts thereof, or the like, cannot be included in the feedstockcompositions. It has been observed that the presence of sulfonic acidgroups in the final acrylonitrile copolymer causes retention of metalions. The feedstock for use in the present process must be substantiallyfree of sulfonic acid groups. By substantially free of sulfonic acidgroups is meant that there is present in the final acrylonitrilecopolymer not more than 0.5 mole % sulfonic acid groups. Also, whensulfonic acid groups are replaced by carboxyl groups in the finalacrylonitrile copolymer, the densification rate during PANOX fiberpreparation is increased.

When precipitation polymerization is employed, fibers can be subjectedto wet spinning without any pre-treatment. Wet spinning is preferredbecause it yields round fibers which give better physical properties tothe final carbon fiber. If wet spinning is performed, care must be takento avoid the use of metal or metal-ion containing solvents. Aqueoussodium thiocyanate and aqueous zinc chloride should not be employed inthe wet-spinning process. Examples of preferred solvents for wetspinning are dimethyl sulfoxide, dimethylformamide, dimethylacetamide,tetramethylene cyclic sulfone, aqueous ammonium thiocyanate and aqueousethylene carbonate.

The densification activator must be free of metal or metal ions. Thedensification activator is a member selected from the group consistingof ammonia and low molecular weight primary or secondary amines. By lowmolecular weight amine is meant a C1 to C6 aliphatic amine.

The objective of the densification step in the preparation of PANOXfiber or carbon fiber is to increase the density of the fiber to about1.4 g/cc. The PAN-fiber, prior to densification, has a density of about1.18 g/cc. Two factors that contribute to increase in density of thefiber during the densification step are: (1) removal of volatilecomponents, and (2) cross linking of the polyacrylonitrile copolymer.

A requirement for a more efficient densification step in the process forpreparing PANOX fiber or carbon fiber is the formation of crosslinks inthe precursor polyacrylonitrile copolymer. The sticking temperature ofthe copolymer is raised in proportion to the number of crosslinks formedin the copolymer. Broadly, the sticking temperature of polymer particlesin a fluidized bed is defined as the temperature at which fluidizationceases due to agglomerization of the particles in the bed. A polymer canbe inherently sticky due to its chemical or mechanical properties orpass through a sticky phase during the production cycle. The flow factorreferences the flow of all materials to that of dry sand. On a scale of1 to 10, dry sand scores a 10. Sticky polymers are usually 1-3, and freeflowing polymers are usually 4-10.

In the present process, effective cross-links are obtained by the use ofammonia. If air is employed as the sole activator, as in the prior artprocesses, the polyacrylonitrile copolymer itself is degraded, givingmixtures of amines. Amines cause formation of amidines by reactions withcyano groups in the polyacrylonitrile copolymer. However, the mixture ofamines causes formation of non-homogeneous crosslinks. Non-homogeneouscross-links result in uneven physical properties throughout the fiber.The use of ammonia as sole activator assures formation of homogeneouscross-links.

An increased amount of carboxylic acid groups in the PAN copolymerallows for retention of more ammonia activator. Once the fusion point ofthe PAN copolymer is reached (about 280.degrees C.), heat release of thecopolymer skyrockets, reaching extremely high exothermic conditions.Rapid release of volatiles leads to poor physical properties in thecarbon fiber product. If there is a relatively low amount of ammoniumion retained by the copolymer, heat release of the copolymer climbsrapidly to high exothermic conditions once the fusion temperature isreached.

An advantage of the ammonia is that it leaves no residue uponcross-linking. Cross-linking agents containing metal cations such assodium, potassium or zinc leave a residue after reaction. PAN fiberscross-linked in the presence of ammonium ion reach an end point densityof 1.4 g/cc more quickly than fibers cross-linked in the presence ofsodium ions. Also, PAN fibers prepared from copolymers devoid of neutralmonomers such as methyl methacrylate are more readily crosslinked.Increased density of the PAN fiber depends upon two factors: (1) amountof ammonium ion activator present in the PAN fiber, and (2) surface areaof the fiber. A fiber with a large surface area is much more difficultto crosslink.

In an embodiment, the present invention relates to a PANOX fiber. ThePANOX fiber is prepared according to a process comprising: obtaining anacrylonitrile copolymer, wherein the copolymer comprises about 92% byweight to about 98% by weight acrylonitrile monomer and about 2% byweight to about 8% by weight vinyl carboxylic acid monomer, and whereinthe acrylonitrile copolymer is substantially free of components selectedfrom the group consisting of metals, metal ions and vinyl sulfonic acidmonomers; adding the acrylonitrile copolymer to a solvent which is amember selected from the group consisting of DMF and DMAC to obtain anemulsion; and adding the emulsion to a wet spinning zone, wherein thewet spinning zone comprises a die plate. The process further comprisesthe steps of spinning the emulsion through the die plate to obtaingelled filaments, wherein the gelled filaments have a substantiallycircular cross-section; adding the gelled filaments to an aqueousimbibation bath, wherein the filaments are under minimum tension, andwherein the aqueous imbibation bath comprises an activator which is amember selected from the group consisting of low molecular weightprimary amine, low molecular weight secondary amine and ammonia; andimbibing the gelled filaments with the activator to obtainactivator-loaded gelled filaments. The process further comprises thesteps of withdrawing the activator-loaded gelled filaments from theaqueous imbibation bath; bundling the activator-loaded gelled filamentsto obtain an activator-loaded fiber; and adding the activator-loadedfiber to a solvent extraction zone. The solvent extraction zonecomprises an aqueous draw bath and a device for drawing the fiber.Preferably, the device for drawing the fiber is a set of tensioningrolls. In an alternative embodiment, a plurality of sets of tensioningrolls can be employed as the device for drawing the fiber. Solvent isremoved from the activator-loaded fiber in the solvent extraction zone.The activator-loaded fiber is drawn on the drawing device in a range ofabout 7× to about 9× its original length while in the aqueous draw bathto obtain a drawn fiber. The drawn fiber has a density of about 1.18grams per cubic centimeter. The process further comprises adding thedrawn fiber to a rapid densification unit; and heating the drawn fiberfor about 8 minutes to about 15 minutes. Preferably, the heating isconducted by employing a heating cycle beginning at about 190 degrees C.and ending at about 400 degrees C. A PANOX fiber is obtained, thedensity of the PANOX fiber being in a range of about 1.40 grams percubic centimeter to about 1.5 grams per cubic centimeter. In anembodiment, the PANOX fiber can be added to a carbonization unit andheated in an inert atmosphere at a temperature in a range of about 1000degrees C. to about 2000 degrees C. or above for a time of about one totwo minutes to obtain a pristine carbon fiber.

The present invention relates to an apparatus for preparing PANOX fiber.The apparatus comprises: a spin dope formation unit, a spinning unit, anaqueous imbibation unit, a solvent extraction unit, and a rapiddensification unit. The apparatus further comprises: a first transfermeans operatively connecting the spin dope formation unit to thespinning unit, a second transfer means operatively connecting thespinning unit to the aqueous imbibation unit, a third transfer meansoperatively connecting the aqueous imbibation unit to the solventextraction unit, and a fourth transfer means operatively connecting thesolvent extraction unit to the rapid densification unit.

The rapid densification unit of the apparatus preferably comprises a setof three heating rolls. The set of three heating rolls comprises a firstheating roll maintained at a temperature of about 235 degrees C. toabout 245 degrees C., a second heating roll maintained at a temperatureof about 245 degrees C. to about 255 degrees C., and a third heatingroll maintained at a temperature of about 255 degrees C. to about 265degrees C.

In a preferred embodiment, the first heating roll is maintained at atemperature of about 240 degrees C., the second heating roll ismaintained at a temperature of about 250 degrees C., and the thirdheating roll is maintained at a temperature of about 260 degrees C.

EXAMPLE

Into a round bottom 1000 ml flask, equipped with a magnetic stirrer, isadded 500 ml distilled water. Acrylonitrile in an amount of 1,235 g(23.3 moles) is added to the water. Itaconic acid in an amount of 65 g(0.5 moles) is added to the aqueous solvent. A catalytic amount ofammonium persulfate and potassium bisulfite is added to the aqueoussolvent. A micro-amount of catalytic iron (about 10 ppm) is also addedto the aqueous solvent.

The aqueous mixture of acrylonitrile, itaconic acid, ammoniumpersulfate, potassium bisulfite, and iron is stirred for about 15minutes. The stirred solution is then removed to an aluminum shellreactor, the reactor surrounded by a water-jacket shell. The reactor isheated to about 80° C. for a time of about 30 minutes. A copolymer ofacrylonitrile and itaconic acid is formed as by a precipitationpolymerization. Heat of reaction is controlled by the water jacketshell.

After the precipitation polymerization reaction is complete, the aqueousdispersion of PAN copolymer is removed from the reaction mixture byfiltration. A filter cake comprising the PAN copolymer is formed.

The filter cake is re-slurried in distilled water. The water is thendecanted off. The PAN copolymer is then dried to a powder in a dryingunit.

Powder of PAN copolymer is added to a MARCO MIXER, along withdimethylformamide (DMF) which is sprayed into the mixer. Mixing begins,as the temperature is increased to 100° C. The mixture of copolymer andDMF is continuously stirred for about 1 hour.

After an hour, the coagulation bath of PAN and DMF has a consistency ofhoney. The coagulation bath is transferred to a wet spinning unit forextrusion through a die plate containing 2100 holes. The wet spinningoperation is conducted at a temperature of about 50° C. Fine gelfilaments of PAN copolymer are obtained from the wet spinning unit.

Gelled filaments are transferred to an imbibation bath comprising waterand ammonia. The temperature of the imbibation bath is about 60 degreesC. The ammonia is present in an amount of about 10 volume %.

After removal from the imbibation bath, gelled filaments, which areloaded with ammonia in the form of the ammonium salt of a carboxylicacid group, are added to a bundling device such as an uptake roll wherethey are bundled or combined to obtain an activator-loaded PAN fiber.

Activator-loaded PAN fiber is then removed to a solvent extraction zonecomprising an aqueous bath and a fiber drawing unit. The fiber drawingunit is within the aqueous bath. The fiber drawing unit is a set oftensioning rolls. The aqueous bath is heated to a temperature of about100° C. While immersed in the bath, the PAN fiber is drawn about 7×.Also, solvent is removed from the PAN fiber.

Drawn PAN fiber, which is substantially solvent-free, is withdrawn fromthe solvent extraction zone. The PAN fiber is taken up by a set ofrelaxation rollers, operating at a temperature of about 100° C., andcoated with water.

The relaxed PAN fiber is transferred to a rapid densification unit. Therapid densification unit comprises a set of three heated rollers. Thefirst heated roller is maintained at a temperature of about 240° C. thesecond heated roller is maintained at a temperature of about 250° C. Thethird heated roller is maintained at a temperature of about 260° C. Therelaxed PAN fiber passes over the three rollers at a speed of about 5ypm (yards per minute). A PANOX fiber is removed from the third heatedroller by an uptake roll.

While the invention has been described by a specific example and variousembodiments, there is no intent to limit the inventive concept except asset forth in the following claims.

I claim:
 1. A PANOX fiber including activator-loaded gelled filaments,the fiber prepared according to the process comprising: (a) obtaining anacrylonitrile copolymer, wherein the copolymer comprises about 92% byweight to about 98% by weight acrylonitrile monomer and about 2% byweight to about 8% by weight vinyl carboxylic acid monomer, and whereinthe acrylonitrile copolymer is substantially free of components selectedfrom the group consisting of metals, metal ions and vinyl sulfonic acidmonomers; (b) adding the acrylonitrile copolymer to a solvent which is amember selected from the group consisting of DMF and DMAC to obtain anemulsion; (c) adding the emulsion to a wet spinning zone, wherein thewet spinning zone comprises a die plate; (d) spinning the emulsionthrough the die plate to obtained gelled filaments, wherein the gelledfilaments have a substantially circular cross-section; (e) adding thegelled filaments to an aqueous imbibition bath, wherein the filamentsare under minimum tension, and wherein the aqueous imbibition bathcomprises an activator which is a member selected from the groupconsisting of low molecular weight primary amine, low molecular weightsecondary amine and ammonia; (f) imbibing the gelled filaments with theactivator to obtain activator-loaded gelled filaments; (g) withdrawingthe activator-loaded gelled filaments from the aqueous imbibition bath;(h) bundling the activator-loaded gelled filaments to obtain anactivator loaded fiber; (i) adding the activator-loaded to a solventextraction zone comprising an aqueous draw bath and a device for drawingthe fiber, wherein solvent is removed from the activator-loaded fiber;(j) drawing the activator-loaded fiber to obtain n7 times to about 9times, while in the aqueous draw bath to obtain a drawn fiber, whereinthe drawn fiber has a density of about 1.18 grams per cubic centimeter;(k) adding the drawn fiber to a rapid densification unit; and (l)heating the drawn fiber for about 8 minutes to about 15 minutes, whereinthe heating is conducted by employing a heating cycle beginning at about190 degrees C., and ending at about 400 degrees C., to obtain the PANOXfiber, and wherein the density of the PANOX fiber is in the range ofabout 1.40 grams per cubic centimeter to about 1 5 grams per cubiccentimeter.